1996 Windstar 3.8 Alternator

This Windstar has eaten 5 alternators in less than a year!!! First one (origional) lasted over 7 years and 107,000 miles. 4 rebuilts and just ordered the 2nd new one today. You can't mount it wrong, due to the three bolt mounting and they are all 130 AMP. I have replaced the belt, water pump, tenisioner, tensioner pulley, idler pulley. All of these parts have less than 200 miles on them, and it still eats alternators--it chews up the brush and spits out the carbon just under the pulley on the mainframe.
The power steering pump and the AC compressor are the only associated units that I haven't replaced. I did notice that the PS pump has about 5/16" end play, so I bought a new one and it has 1/4" end play.

PLEASE HELP, these things are over $200.00 each and I'm running out of suppliers that will warranty them!!

Thanks in advance,
LWR

Howdy, I would suggest you stop buying these rebuilt Alternators from whoever is selling them to you.
Most rebuilders only care about replacing parts so that they last as long as their warrenty 60 days.I would suggest you take your alternator to a local electrical shop they will rebuild it so it lasts or go to a local junk yard.This is from experiance I used to buy rebuilt all the time until I got wise, the last time an alternator went on me I took it to a local electrical shop fixed it for $19.00 (no problem, since).bottom line stop buying other peoples junk.

If you buy a rebuilt you should get one at advance auto parts if this store is in your area. They have one with a lifetime warranty for 183 dollars. They also have an oem ford rebuilt with a 3 yr 36k mile warranty for 132 dollars. You can also order online. The web address is advanceautoparts.com

I have never had good luck with rebuilt or remanufactured alternators or starters for any make model :banghead: . I've had rebuilt starters last as little as a few weeks! It may be near impossible for a ford, but If you can get a new factory/dealer replacement, that's the way to go. They are 2 to 3x the price of a reman, but it will be the last one you'll put in.
G/luck
Joel

i have never had any problems with the rebuilt ones. As a matter of fact one time i went to one of those u-pull it junk yards and i took one of from a crown vic. It look like it was just replaced before they junked the car. i paid 10 bucks. To make a long story short. A few weeks later my alternator went out. I used this one and i never had a problem.